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2 Co p y r i g h t Copyright 008 by Eclipse, Inc. All rights reserved worldwide. This publication is protected by federal regulation and shall not be copied, distributed, transmitted, transcribed or translated into any human or computer language, in any form or by any means, to any third parties, without the express written consent of Eclipse, Inc. In accordance with the manufacturer s policy of continual product improvement, the product presented in this brochure is subject to change without notice or obligation. Disclaimer Notice The material in this manual is believed adequate for the intended use of the product. If the product is used for purposes other than those specified herein, confirmation of validity and suitability must be obtained. Eclipse warrants that the product itself does not infringe upon any United States patents. No further warranty is expressed or implied. We have made every effort to make this manual as accurate and complete as possible. Should you find errors or omissions, please bring them to our attention so that we may correct them. In this way we hope to improve our product documentation for the benefit of our customers. Please send your corrections and comments to our Marketing Communications Manager. Liability a n d Wa r r a n t y It must be understood that Eclipse s liability for its product, whether due to breach of warranty, negligence, strict liability, or otherwise is limited to the furnishing of replacement parts and Eclipse will not be liable for any other injury, loss, damage or expenses, whether direct or consequential, including but not limited to loss of use, income, or damage to material arising in connection with the sale, installation, use of, inability to use, or the repair or replacement of Eclipse s products. Any operation expressly prohibited in this guide, any adjustment, or assembly procedures not recommended or authorized in these instructions shall void the warranty.

3 About This Manual Au d i en c e This manual has been written for people who are already familiar with all aspects of this product. These aspects are: Installation Use Maintenance The audience is expected to have had previous experience with this kind of equipment. Purpose This manual contains essential information for the proper installation and operation of the monitoring system. Read this manual carefully. Make sure that you understand its structure and contents. Obey all the safety instructions. Do not deviate from any instructions or application limits in this manual without written consent from Eclipse, Inc. If you do not understand any part of the information in this manual, do not continue. Contact Eclipse.

4 Do c u m e n t Co n v e n t i on s There are several special symbols in this document. You must know their meaning and importance. The explanation of these symbols follows below. Please read it thoroughly. Danger: Indicates hazards or unsafe practices which WILL result in severe personal injury or even death. Only qualified and well trained personnel are allowed to carry out these instructions or procedures. Act with great care and follow the instructions. Warning: Indicates hazards or unsafe practices which could result in severe personal injury or damage. Act with great care and follow the instructions. Caution: Indicates hazards or unsafe practices which could result in damage to the machine or minor personal injury, act carefully. Note: Indicates an important part of the text. Read thoroughly. Ho w To Ge t He l p If you need help, contact your local Eclipse representative. You can also contact Eclipse at: 665 Elmwood Rd. Rockford, Illinois 60 U.S.A. Phone: Fax:

7 Introduction Product Description The Eclipse Veri-Flame Single Burner Monitoring System controls the start-up sequence and monitors the flame of single gas, oil, or combination gas/oil burners. There are three different models of the Veri-Flame line: no purge, purge and modulation models. Each model features field selectable trial for ignition (TFI). Each model is also available for use with three types of flame sensor: ultraviolet (UV), self-check UV and flamerod. Required components are the Veri-Flame, matching wiring base and a flame sensor. Optional components include a remote display and cable, tester, and various scanner accessories. The Veri-Flame No Purge and Purge models are available in three different series 560, 560 and The 560 Series is UL listed for the USA and Canada and FM approved; the 5605 Series is UL listed and FM approved. The 560 Series is for 0VAC applications and is FM approved. Please see instruction manual 88- for European CE marked versions. The Veri-Flame Modulation model is available in two different series: 560 and 560. Both series are capable of modulation (high purging and low fire start). The 560 Series is UL recognized for the USA and Canada and FM approved. The 560 Series is for 0VAC and is FM approved. Figure. Veri-Flame Single Burner Monitoring System (Purge Unit Shown) 7

10 DIP Switch Selection In t r o d u c t i on This section details the location, selection and description of the Veri-Flame DIP switches, which allow for sequence and timing functions as well as system configuration. Caution: To avoid electric shock, shut off the power supply when installing or removing any control device. Flame monitoring systems must be installed by a qualified, licensed technician. DIP Sw i tc h Lo c at i on DIP Sw i tc h Ac c e s s No Pu r g e DIP Sw i tc h Se t t i n g s Mo d u l at i on & Pu r g e DIP Switch Settings All of the DIP switches are located in the back of each Veri-Flame unit (see Figure. on page, or the photograph on page 7). To gain access to the DIP switches, the Veri-Flame must be separated from the back box (for visual reference, please refer to Dimensions on page 9). This separation will expose the DIP switches on the back of the Veri-Flame unit. No Purge models of the Veri-Flame only use three of the eight DIP switches, as shown in the labels in Figure. on page. They are as follows: SW: Recycling mode selection (On=Recycling; Off=Non-recycling) SW: Pilot selection (On=Intermittent, where pilot remains on during burner cycle; Off=Interrupted, where pilot valve closes after main burner is established). SW: Trial-for-ignition (TFI) range selection (For 560/560 units: On=0 seconds; Off=5 seconds. For 5605 units: On=0 seconds; Off=5 seconds). Modulation and purge models of the Veri-Flame use all of the eight DIP switches, as illustrated in Figure. on page. They are as follows: SW: Recycling mode selection (On=Recycling; Off=Non-recycling) SW: Pilot selection (On=Intermittent, where pilot remains on during burner cycle; Off=Interrupted, where pilot valve closes after main burner is established). SW: Trial-for-ignition (TFI) range selection (For 560/560 units: On=0 seconds; Off=5 seconds. For 5605 units: On=0 seconds; Off=5 seconds). SW through 7: Purge time selection. Total purge time is the sum of each switch selected. If all are set off, the trial for ignition starts when the air switch input comes on. SW8: Post purge selection. (On=5 second post purge). 0

11 Figure. DIP Switch Location Close-up of DIP switches on back side of all Veri-Flame models. Figure. DIP Switch Labels with Selections No Purge Models c us Purge Models Modulation Models c us c us

12 Function Summary In t r o d u c t i on Standard Features In t e r l o c k s & Limit Sw i tc h In p u t (Terminal 7) Co m b u s t i on Air Sw i tc h Input (Terminal 6) Ma in Fu e l Va lv e Cl o s e d Sw i tc h (Terminal V) Low Fire Start This section describes the features of the Veri-Flame. It is divided into three categories: standard features, optional features and the LED indicator lights on the front cover. Refer to Figure 5.5 for sequence diagrams. The following function features are standard on the Veri-Flame models as noted: This input is considered the normal operation control or run input to the Veri-Flame system. Interlocks are generally pressure or temperature switches which, when activated, start the burner. Limit switches are generally pressure, temperature and other switches which, when activated, stop the burner. The interlocks and limit switches are wired in series. A break in this circuit will shut the burner down, but will not produce an alarm. For purge and modulation models: This input is for monitoring the combustion air switch separately from other interlocks and limits. The Veri-Flame checks the air flow switch input is open before start-up, closed during operation, and open again at burner shutdown, thus preventing operation with an air switch that is defective, maladjusted or jumped. This input has about a second delay to filter out and ignore a momentary interruption. The input will be proven open before start-up and after shutdown. If the input is improperly powered before the fan output is energized, the system error light will blink. The input must de-energize within 0 seconds or the Veri-Flame will lockout. After the fan output has energized, the air switch input must be made within 0 seconds. If not proven, then the system will lockout, the alarm output and the air failure light will come on. However, if the unit has the optional air switch input hold feature, the sequence is held indefinitely without causing a lockout. When the air switch input is made, then the sequence continues. If the air switch opens during the main firing cycle, the system will either lockout or recycle, depending on the DIP switch recycle selection. For purge and no-purge models: The Veri-Flame can be interlocked with the main valve closed switch. This feature checks the switch position before start-up and after shutdown to insure proper valve operation when the jumper on the base is cut. For modulation models: When wired, the system checks for the low fire start position prior to light-off.

13 Ma in Fu e l Va lv e Cl o s e d/ Hi g h Fi r e Pu r g e Ch e c k (Terminal D) Recycle Mode Test Mode (Button In) Pilot Test Mode In t e r r u p t e d o r Run Mode (Button Out) Intermittent Pilot Post Purge Spa r k, Pi l o t, Fl a m e & Main Flame Separation Sy s t e m Er r o r s & Lockout Conditions For modulation models: This feature is enabled when the jumper on the base is cut. The system checks that the high fire position switch and the main valve closed switch are both made at the end of the high fire purge. For all models: When selected, the Veri-Flame will restart the sequence after flame or air failure. The recycle mode allows the system to re-initiate the start-up sequence automatically provided the main burner has been operating for at least 5 seconds. If the pilot flame fails to light during recycling, the system will lock out and annunciate a pilot flame fail. If the recycle is successful and the main burner is operational for at least 5 seconds, the system is ready for another recycle. At no time will the system recycle in the event of pilot flame fail. For all models: This mode is entered by depressing the TEST/ RESET button on the front cover. In the pilot test mode, the Veri- Flame will hold the sequence once the pilot flame is established (i.e., the main valve is not energized). When in the pilot test mode, the green Interlocks Closed light blinks. To exit the pilot test mode, push the TEST/RESET button three times (the green Interlocks Closed light stops blinking but remains lit) and the Veri-Flame will restart the sequence. For all models: Pilot mode is selected using the DIP switch SW. An interrupted pilot shuts off 0 seconds after the main valve opens. An intermittent pilot continues during the entire main flame firing cycle. For purge and modulation models: Post purge is enabled by DIP switch SW8. A post purge maintains the combustion air fan output for 5 seconds after the interlocks and limit switch input have opened. For all models: During the trial for ignition period (TFI), the pilot valve and ignition coil remains energized. If a flame signal is present at the end of the TFI, the pilot output remains on and the ignition coil is de-energized. After a five second delay to prove the pilot flame, the main gas valve is energized. A system error (illuminated by the red System Error LED on the front cover) prevents gas ignition. The unit will continue its sequence after the error is cleared. A lockout condition energizes the alarm output and de-energizes the gas valve and ignition outputs. The unit must be reset to clear the alarm and start the sequence. To reset, the button must be pressed twice so that the button is in the out position. The following system errors result in immediate lockout conditions: Wiring error which puts external voltage on the output terminals (for all models). Welded internal contacts or other malfunctions in the Veri-Flame (for all models). Main fuel valve (for all models) open after cycle shut down or before start-up. The system error light blinks twice and then remains on. The fan output terminal 8 will energize. Low fire fail (for modulating model) low fire switch open prior to trial for ignition. High fire fail (for modulating model) high fire switch is not closed at the end of high fire purge.

14 Sy s t e m Er r o r s & Lockout Conditions (Co n t i n u e d) Hi g h to Lo w Fi r e Pu r g e Mo d u l at i on Ca pa b i l i t y w i t h Hi g h to Lo w Fi r e Po s i t i on Sw i tc h In t e r l o c k s Optional Features The following situations will result in a lockout condition: Air failure (for purge and modulation models) loss of combustion air anytime during the operational cycle. The Air Failure LED will be on for this condition. (See Recycle Mode on page.) Pilot flame fail (for all models) loss of flame during the trial for pilot ignition period. The Flame Failure LED will be on for this condition. Main flame fail (for all models) loss of flame during the main burner trial for ignition or run period (recycling not selected). The Flame Failure LED will be on for this condition. The following result in lockout conditions after 0 seconds, the system error light blinks about times and then remains on: 9. If a flame is detected out of sequence, which may be caused by: a. A faulty scanner (for all models) b. Electrical interference on the sensor wiring (for all models) c. A flame exists in the burner or in the line of sight of a scanner, due to a gas leak, product fire or other conditions (for all models) 0. Air flow switch closed before start-up (for purge and modulation models). For modulation models: The modulation feature incorporates a high fire purge time and a low fire purge time into the purge sequence. This feature allows the Veri-Flame to sequence internal dry contacts which can be used by the customer requiring a high fire purge of the combustion chamber before ignition. The high fire and low fire purge times are selectable by means of DIP switches (see Section, DIP Switch Settings on page 0): SW 5 seconds SW6 60 seconds SW5 0 seconds SW7 0 seconds The selected times are additive and apply to both the high fire and low fire purge times (that is, high and low fire times are always identical). The modulation terminals will sequence as follows: Sequence Step Internal Contact Connections Power Off Terminal 0 (Common) Terminal (Low Fire) Power On, Limits Open Terminal 0 (Common) Terminal (Low Fire) Purge to High Fire Terminal 0 (Common) Terminal (High Fire) Purge to Low Fire Terminal 0 (Common) Terminal (Low Fire) Automatic Modulation Terminal 0 (Common) Terminal (Auto) Alarm & Lockout Terminal 0 (Common) Terminal (Low Fire) The purge to high fire sequence does not start until the air switch input is on. The Automatic step occurs when the burners are operating and allows the burner firing rate to be controlled by an automatic temperature controller. The following features are available on select models, or when optional equipment is purchased.

15 Air Switch Input Hold Re m o t e Di s p l ay & Power Supply Stat u s Li g h t s & Pu s h-bu t t o n For purge models: Holds the sequence indefinitely until air switch input is confirmed without affecting the air failure function and causing a lockout. The model 560DBP operates on 0VAC and has a keypad for reset function. The display is door panel mounted and features a liquid crystal display in a / DIN housing. The unit connects to the Veri-Flame by a cable to the flame signal test jack, and receives a serial communication on each sequence state change. The display incorporates the following functions:. Provides status messages for the Veri-Flame sequence (see section 9).. Indicates lockout conditions when they occur, as well as the amount of time into the sequence when the lockout occurred (see section 9).. Provides continuous monitoring of the burner s flame signal strength and run time during main burner operation. All of the status lights and the TEST/RESET push-button are located on the front cover of the Veri-Flame. This section describes their respective functions. Interlocks Closed For all models: This green LED illuminates when the operation limits are made. These limits are wired in series to terminal 7. This input becomes energized to begin the burner sequence. When in the test mode, this LED blinks (see Pilot Test Mode on page ). Air Failure For purge and modulation models: This red LED illuminates whenever combustion air is lost during the operational cycle of the Veri-Flame. System Error For all models: This red LED illuminates when a system error is detected (see System Errors & Lockout Conditions on pages ). Flame Failure For all models: This red LED illuminates when a pilot or main flame fails. Low Fire For modulation models: This yellow LED illuminates during the low fire period of the purge cycle. High Fire For modulation models: This red LED illuminates during the high fire period of the purge cycle. Auto For modulation models: This green LED illuminates during the automatic period which occurs 0 seconds after the main valve is energized. Test/Reset For all models: This push-button is used to activate the pilot test mode or to reset the Veri-Flame unit. Flame Signal For all models: This red LED is located behind the signal test port and illuminates when a flame signal is present. 5

16 System Installation 5 In t r o d u c t i on In t e r l o c k s & Limit Switch Input Co m b u s t i on Air Switch Input To Fan Output Terminal FAN To Fan Output Terminal Air Switch Open -Way Solenoid Valve De-energized To Burner Air Switch Closed FAN To Burner -Way Solenoid Valve Energized In this section, the necessary procedures are detailed to integrate a Veri-Flame into a burner system; Figures 5. and 5. illustrate the various terminal strips mentioned. Note: Shut off the power supply before the Veri-Flame is removed or replaced from the base. Caution: Installation and maintenance must conform with the National Electrical Code and all other national and local codes and authorities having jurisdiction. Flame monitoring systems must be installed by a qualified, licensed technician. Wire external interlock, control, and limit switches in series to this input. Guard against induced voltage levels to wiring connected to this input. In some extreme wiring runs, reduction of induced voltages may require a load (relay or light) connected to terminal 7 to avoid system error lockouts. This input is the power source for the valve and ignition output terminals. Be sure all switches wired to this input can handle the current required by the total of all loads connected to terminals,, and 5. For purge and modulation models: Wire any switches and contacts in series to this terminal for proving air flow function and relating to the air failure light. Power must not be immediately present at terminal 6 when power is first applied to terminals or 7. If this terminal is not used, place a jumper between the combustion blower output (terminal 8) and the air switch input (terminal 6). If the combustion air blower is controlled outside of the Veri-Flame system, then a three way solenoid valve must be connected between the air switch port and the blower sensing port. The valve de-energized state should vent the switch to ambient pressure. The energized state then connects the air switch to the blower sensing port. Power the valve from the blower output terminal 8. If accepted by local codes, the air switch could be wired between the combustion blower output and the air switch input. Connecting the air switch in this manner will satisfy the open contact (air short) check on the switch. 6

17 Ignition Wiring Low Fire Input Ma in Va lv e Cl o s e d Sw i tc h High Purge Input Remote Reset Re m o t e Di s p l ay & Power Supply Route ignition wiring a sufficient distance from all sensors and other low voltage wiring to avoid electrical interference, which may cause erratic operation of the Veri-Flame system. Keep the high voltage wire run from the ignition transformer as short as possible. The best condition is to mount the ignition transformer close to the burner and keep a low impedance path from the burner ground to the case of the transformer. Make sure the high voltage lead and ground return paths do not create a loop antenna around the Veri-Flame and sensor wiring. For modulation models: It is possible to wire the system for checking low fire start position prior to pilot ignition. To use this feature, the low fire start switch must be connected between terminal and the pilot valve (see Figure 5.). On direct spark burners, a by-pass contact must be wired around the low fire switch, see relay and contact CR in Figure 5.. The system can be wired to check for the main valve closed switch on the main gas valve prior to start-up and after the end of the burner cycle. For purge and no purge models: The main valve closed switch must be connected to Terminal V and the jumper in the base must be cut (see Figure 5.). For modulation models: The main valve closed switch must be wired in series between the air flow switch and the high purge damper switch (see Figure 5.). To use this feature, the jumper in the base must be cut. For modulation models: The system can be wired to check for high purge position during the high fire purge portion of the sequence. To use this feature, the red jumper in the base must be cut and the high purge position switch must be connected from terminal 6 to D. If this feature is not used, the jumper in the base remains intact or a jumper must be installed between terminals and D. Please note that the yellow jumper on the base has no effect whether cut or intact. This feature permits remote mounting of a switch to reset the Veri-Flame. To use this feature, a normally closed remote reset switch must be wired so power is interrupted to terminal. When it is depressed or actuated, the connection to terminal is momentarily interrupted and resets the Veri-Flame. Wire the display according to figure 5.. Mount through a / DIN cutout using the two supplied brackets in either the top and bottom or the side slots. Locate the display and wiring to minimize electrical interference. Applying and disconnecting the display power supply should coincide with power to terminal of the Veri-Flame. Use the appropriate cable (Eclipse part #08) to connect to the test jack and to the S terminal of the Veri-Flame wiring base. Do not attempt to parallel the test jack signal to other devices when using a remote display. The LCD display contrast can be adjusted on the back with a small blade screwdriver. Note: Power for terminal 7 of the Veri-Flame must not flow through the R-R contact of the remote display when load currents exceed 5 amps. 7

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